Current collector plates of bulk-solidifying amorphous alloys

ABSTRACT

Collector plates made of bulk-solidifying amorphous alloys, the bulk-solidifying amorphous alloys providing ruggedness, lightweight structure, excellent resistance to chemical and environmental effects, and low-cost manufacturing, and methods of making such collector plates from such bulk-solidifying amorphous alloys are provided.

FIELD OF THE INVENTION

The present invention relates to current collector plates made ofbulk-solidifying amorphous alloys, and methods of making such currentcollector plates from bulk-solidifying amorphous alloys.

BACKGROUND OF THE INVENTION

A fuel cell is a device used to generate electricity by the chemicalreaction of hydrogen gas or other suitable hydrocarbons. A fuel cellgenerally consists of an electrolyte sandwiched between two electrodes.During operation, hydrogen or other forms of fuel passes over oneelectrode (the anode), and oxygen or air passes over the other electrode(the cathode) to produce electricity and water and heat as thebyproducts. At a molecular level a catalyst at the anode splits animpinging fuel into a positively charged ion and an electron, each ofwhich take different paths to the cathode. When the fuel is hydrogen,the hydrogen atom splits into a proton and an electron. The protons passthrough the electrolyte to the cathode, while the electrons arecollected to form a current that can be utilized, as electrical power,before they return to the cathode via an external means. At the cathodethe protons, electrons, and oxygen are combined, with the aid of acatalyst, to form water. Heat and water are the only byproducts of thischemical process that need to be removed from the fuel cell.

Common types of fuel cell are: Phosphoric Acid Fuel Cells (PAFC), MoltenCarbonate Fuel Cells (MCFC), Alkaline Fuel Cells (AFC), Proton ExchangeMembrane Fuel Cells (PEMFC), Direct Methanol Fuel Cell (DMFC) and SolidOxide Fuel Cells (SOFC). Fuel cells may operate at lower temperatures(about 250° C. or less), or at higher temperatures (about 500° C. orgreater) depending on their specific type. Lower operating temperaturefuel cells include PAFC, AFC, and PEMFC.

Although generally each individual unit fuel cell comprises a membrane(electrolyte) assembly and catalysts interposed between electricallyconductive current collector plates, in actual operation mode, multipleunit cells are arranged in series to form a fuel cell stack to meetvoltage and/or power requirements. When the individual cells arearranged in series to form a fuel cell stack, the current collectorplates are generally referred to as bipolar collector plates, flow-fieldplates or collector-separator plates. In such an arrangement, thebipolar plate is generally a single plate with one side acting as thecathode and the other side acting as the anode, where each side actsseparately as a collector plate (as a cathode or anode) of twoneighboring units. In some cases, the bipolar plate can be thought of ascomprising different components including a separator plate, which issandwiched between the cathode and the anode side belonging to theneighboring unit cells. In such a device the separator plates acts as aboundary from one cell to the next cell. There are different variationsof the collector plates. For example, the current collector acting asthe cathode or anode can be a single plate. Another example is that thecurrent collector, acting as the cathode or anode, and the separator canbe a single plate. For simplicity, such plates will be called thecollector plates in this invention, which can be the current transferor,separator, cathode, anode, end plate, or any combination thereof.

Regardless of the ultimate form of the collector plates, such platesperform multiple functions that are critical for the entire operation ofthe fuel cell. First, the collector plates provide a structural supportand electrical connection between unit cells. In the case of a singleunit fuel cell, the collector plate (which is also the end plate) isconnected electrically to an electrical load. Second, the collectorplates direct and distribute fuel, and/or oxidant reactants, and/orcoolant to, away from, and within unit cells. Third, the collectorplates remove products from unit cells and separate fuel and oxidant gasstreams between electrically connected cells. In addition to beingelectrically conductive, collector plates must have good mechanicalstrength, high resistance to degradation caused by chemical attackand/or hydrolysis, and low permeability to hydrogen gas.

Typically, collector plates have intricate functional patterns formed onthe majority of its surface area. For example, complex channels withdifferent patterns, sizes, and shapes, are needed for directing fuel,oxidant, coolant, and byproducts through the fuel cell. The design ofthe complex patterns depends greatly on the desired pressure drop,resident time, and flow rate. A single channel design would increasepressure drop and resident time, but decrease the flow rate. A multiplechannel design would decrease the pressure drop and resident time, butincrease the flow rate. The typical dimensions, the depth, and the widthof such surface features are on the order of 1 mm, although thesefeatures can be substantially smaller than 1.0 mm or substantiallylarger than 1.0 for special fuel cells. However, such surfaceintricacies cause significant manufacturing problems for materialscommonly used for collector plates.

For example, graphite structures have been traditionally machined to adesired configuration from graphite composite blanks, which is veryexpensive and time consuming due to the nature of such machining.Although polymer based materials have some advantage with regard to theease of manufacturing, the collector plates made of polymer basedmaterials are typically inadequate due to the poor electricalconductivity and low strength of the material, particularly with regardto withstanding the compression force necessary to hold multiple fuelcell unit together in stacking applications. Conventional metals andalloys have also been used in fuel cell, but all suffer significantdeficiencies. For example, using machined ordinary alloys to produce thenecessary detailed surface features has proved to be very expensive.Furthermore, although the lower cost ordinary alloys may be coated witha corrosion resistance layer, which may temporarily solve corrosionproblems, such coatings do not represent a satisfactory solution for thelong-term stability of the fuel cell structure.

Other issues also arise in the use of ordinary alloys. For example,collector plates should have a high tolerance in the flatness andsurface finish of the plate in order to provide an effective seal forthe transport of the fuel and byproducts in the gas and liquid form. Anyleakage of these gas and liquids, especially in stacked units is notacceptable, and is a critical factor in determining the long-termstability of the fuel cell. For example, typical alloys are readilyprone to permanent deformation, such as nicking and denting duringfabrication and assembly, whereas graphite plates are extremely fragilewithout showing any flexibility. Considering the large surface area,high flatness, and small thickness needed in most collector plateapplications, the problems of permanent bending and denting for metallicalloys, and the fragility of graphite base materials become severedeficiencies in producing satisfactorily performing collector plates.

Accordingly, a need exists for improved materials for collector platesand collector plates made of such materials.

SUMMARY OF THE INVENTION

The present invention is directed to a collector plate made of a bulksolidifying amorphous alloy.

In another embodiment of the invention, the collector plate is part of afuel cell assembly. In yet another embodiment of the invention, thecollector plate is at least in part of another plate or fuel cellmaterial.

In still another embodiment of the invention, the collector plate alsofunctions as a tight seal to prevent liquid and gaseous permeation.

In still yet another embodiment of the invention, the collector platecomprises a cathode facing face and an anode facing face with multiplechannels for transporting fuels, reactants, and products.

In still yet another embodiment of the invention, the collector platemay have multiple channels between the cathode facing face and the anodefacing face for heat exchanging purpose.

In still yet another embodiment of the invention, the collector platecomprises two plates, a cathode facing plate and an anode facing platewith multiple channels for transporting fuels, reactants, and products.In such an embodiment, the interfacial surface of the cathode and theanode plate of the adjacent fuel cell unit may comprise multiplechannels for heat exchanging purposes.

In still yet another embodiment of the invention, a gas impervious layermay be place between the cathode and the anode plate to prevent gascross-over from one plate to another.

In still yet another embodiment of the invention, the surface featuresof collector plate has the aspect ratio (depth/width) from 0.1 to 5.

In still yet another embodiment of the invention, the width of thechannels in the collector plate is between 100 (micrometer) to 2000(micrometer).

In still yet another embodiment of the invention, the collector plate ismade of bulk-solidifying amorphous alloy with an elastic strain limit ofabout 1.8% or more.

In still yet another embodiment of the invention, the amorphous alloy isdescribed by the following molecular formula: (Zr, Ti)_(a)(Ni, Cu,Fe)_(b)(Be, Al, Si, B)_(c), wherein “a” is in the range of from 30 to75, “b” is in the range of from 5 to 60, and “c” in the range of from 0to 50 in atomic percentages.

In still yet another embodiment of the invention, the amorphous alloy isdescribed by the following molecular formula: (Zr, Ti)_(a)(Ni,Cu)_(b)(Be)_(c), wherein “a” is in the range of from 40 to 75, “b” is inthe range of from 5 to 50, and “c” in the range of from 5 to 50 inatomic percentages.

In still yet another embodiment of the invention, the amorphous alloycan sustain strains up to 1.5% or more without any permanent deformationor breakage.

In still yet another embodiment of the invention, the bulk solidifyingamorphous alloy has a high fracture toughness of at least 20ksi-in^(0.5).

In still yet another embodiment of the invention, the bulk solidifyingamorphous alloy has a ΔT of 60° C. or greater.

In still yet another embodiment of the invention, the bulk solidifyingamorphous alloy is a ferrous based metals wherein the elastic limit ofthe amorphous alloy is about 1.2% and higher, and the hardness of theamorphous alloys is about 7.5 Gpa and higher.

In another alternative embodiment, the invention is also directed tomethods of manufacturing collector plates from bulk-solidifyingamorphous alloys.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bebetter understood by reference to the following detailed descriptionwhen considered in conjunction with the accompanying drawings wherein:

FIG. 1 a is a schematic of an exemplary embodiment of a collector platein accordance with the present invention.

FIG. 1 b is a schematic of another exemplary embodiment of a collectorplate in accordance with the present invention.

FIG. 2 is a flowchart of an exemplary method of manufacturing acollector plate in accordance with the present invention.

DESCRIPTION OF THE INVENTION

The current invention is directed to collector plates made ofbulk-solidifying amorphous alloys, the bulk-solidifying amorphous alloysproviding ruggedness, lightweight structure, excellent resistance tochemical and environmental effects, and low-cost manufacturing. Anotherobject of the current invention is a method of making collector platesfrom such bulk-solidifying amorphous alloys.

FIGS. 1 a and 1 b are schematic diagrams of typical collector platesmade of bulk solidifying amorphous alloy with intricate flow channelpatterns. As can be observed from the Figures, the actual design of theintricate flow channels may take any form and is only depent on thedesired pressure drop, reaction duration, and optimal flow rate. Forexample, FIG. 1 a shows a single channel design for the transportationof materials, while FIG. 1 b shows a and double channel design.

Bulk solidifying amorphous alloys are a recently discovered family ofamorphous alloys, which can be cooled at substantially lower coolingrates, of about 500 K/sec or less, and substantially retain theiramorphous atomic structure. As such, they can be produced in thicknessesof 1.0 mm or more, substantially thicker than conventional amorphousalloys, which are typically limited to thicknesses of 0.020 mm, andwhich require cooling rates of 10.sup.5 K/sec or more. U.S. Pat. Nos.5,288,344; 5,368,659; 5,618,359; and 5,735,975, the disclosures of whichare incorporated herein by reference in their entirety, disclose suchbulk solidifying amorphous alloys.

A family of bulk solidifying amorphous alloys can be described as (Zr,Ti)_(b)(Ni, Cu, Fe)_(b)(Be, Al, Si, B)_(c), where a is in the range offrom 30 to 75, b is in the range of from 5 to 60, and c in the range offrom 0 to 50 in atomic percentages. Furthermore, these basic alloys canaccommodate substantial amounts (up to 20% atomic, and more) of othertransition metals, such as Nb, Cr, V, Co. A preferable alloy family is(Zr, Ti)_(a)(Ni, Cu)_(b)(3e)_(c), where a is in the range of from 40 to75, b is in the range of from 5 to 50, and c in the range of from 5 to50 in atomic percentages. Still, a more preferable composition is (Zr,Ti)_(b)(Ni, Cu)_(b)(3e)_(c), where a is in the range of from 45 to 65, bis in the range of from 7.5 to 35, and c in the range of from 10 to 37.5in atomic percentages. Another preferable alloy family is (Zr)_(a)(Nb,Ti)_(b)(Ni, Cu)_(c)(Al)_(d), where a is in the range of from 45 to 65, bis in the range of from 0 to 10, c is in the range of from 20 to 40, andd in the range of from 7.5 to 15 in atomic percentages.

Another set of bulk-solidifying amorphous alloys are ferrous metals (Fe,Ni, Co) based compositions. Examples of such compositions are disclosedin U.S. Pat. No. 6,325,868 and in publications to (A. Inoue et. al.,Appl. Phys. Lett., Volume 71, p 464 (1997)), (Shen et. al., Mater.Trans., JIM, Volume 42, p 2136 (2001)), and Japanese patent application2000126277 (Publ. #2001303218 A), all of which are incorporated hereinby reference. One exemplary composition of such alloys isFe₇₂Al₅Ga₂P₁₁C₆B₄. Another exemplary composition of such alloys isFe₇₂Al₇Zr₁₀Mo₅W₂B₁₅. Although, these alloy compositions are notprocessable to the degree of the Zr-base alloy systems, they can stillbe processed in thicknesses of 1.0 mm or more, sufficient enough to beutilized in the current invention.

Bulk-solidifying amorphous alloys have typically high strength and highhardness. For example, Zr and Ti-base amorphous alloys typically haveyield strengths of 250 ksi or higher and hardness values of 450 Vickersor higher. The ferrous-base version of these alloys can have yieldstrengths up to 500 ksi or higher and hardness values of 1000 Vickersand higher. As such, these alloys display excellent strength-to-weightratio especially in the case of Ti-base and Fe-base alloys. Furthermore,bulk-solidifying amorphous alloys have good corrosion resistance andenvironmental durability, especially the Zr and Ti based alloys.Amorphous alloys generally have high elastic strain limit approaching upto 2.0%, much higher than any other metallic alloy.

In general, crystalline precipitates in bulk amorphous alloys are highlydetrimental to the properties of amorphous alloys, especially to thetoughness and strength of these alloys, and as such it is generallypreferred to minimize the volume fraction of these precipitates.However, there are cases in which, ductile crystalline phasesprecipitate in-situ during the processing of bulk amorphous alloys,which are indeed beneficial to the properties of bulk amorphous alloys,especially to the toughness and ductility of the alloys. Such bulkamorphous alloys comprising such beneficial precipitates are alsoincluded in the current invention. One exemplary case is disclosed in(C. C. Hays et. al, Physical Review Letters, Vol. 84, p 2901, 2000),which is incorporated herein by reference.

As a result of the use of these bulk-solidifying amorphous alloys, thecollector plates of the present invention have characteristics that aremuch improved over conventional collector plates made of ordinarymetallic materials. The surprising and novel advantages of usingbulk-solidifying amorphous alloys in producing collector plates will bedescribed in various embodiments below.

First, the combination of high strength and high strength-to-weightratio of the bulk solidifying amorphous alloys significantly reduces theoverall weight and bulkiness of the collector plates of the currentinvention, thereby allowing for the reduction of the thickness of thesecollector plates without jeopardizing the structural integrity andoperation of the fuel cells into which these collector plates areintegrated. The ability to fabricate collector plates with thinner wallsis also important in reducing the bulkiness of the fuel cell andincreasing the efficiency per-volume of the fuel cell. The efficiency ofthe fuel cell also increases because of higher allowable flow rates andthe fact that there more of the surface of the catalyst is used. Thisincreased efficiency is particularly useful for the application of fuelcells in mobile devices and equipment, such as in automobiles and thelike because the less bulky the fuel cell, the easier it is to providestorage for the device on such a mobile device.

Although other high strength and high strength-to-weight ratio materialsmight be considered in the use of collector plates, there are majorfabrication and assembly deficiencies with most such materials. Forexample, one material with high strength and excellentstrength-to-weight ratio is graphite, however, graphite lacks anyflexibility and is therefore actually quite fragile. Another examplewould be conventional metallic alloys, however, most conventionalmetallic alloys are prone to permanent deformation and denting. The verylarge surface area and very small thicknesses of collector plates makessuch problems even more significant. However, bulk-solidifying amorphousalloys have reasonable fracture toughness, on the order of 20ksi-sqrt(in), and high elastic strain limit, approaching 2%.Accordingly, high flexibility can be achieved without permanentdeformation and denting of the collector plate. As such, collectorplates made of bulk-solidifying amorphous alloys can be readily handledduring fabrication and assembly, reducing the cost and increasing theperformance of the fuel cell.

As discussed, bulk solidifying amorphous alloys have very high elasticstrain limits, typically around 1.8% or higher. This is an importantcharacteristic for the use and application of fuel cell collectorplates. Specifically, high elastic strain limits are preferred fordevices mounted in mobile devices, or in other applications subject tomechanical loading or vibration. A high elastic strain limit allows thecollector plate to take even more intricate shape and to be thinner andlighter. High elastic strain limits also allow the collector plates tosustain loading and flexing without permanent deformation or destructionof the device.

Furthermore, high strength, high hardness and high elastic strain limitcharacteristics of bulk amorphous alloys provide better performance anddurability for the seal joints of the collector plates providing longerlifetime and lower maintenance. The combination of a strength higherthan 200 ksi, a hardness more than 400 Vickers, and an elastic strainlimit higher than 1.5% of bulk amorphous alloys provides durability notonly for the seal joints, but also for the whole collector plate ingeneral during handling, assembly and service.

Bulk amorphous alloys have reasonably good electrical conductivity,about 5000 S/cm in the case Zr/Ti base alloys, and this relatively highelectrical conductivity can improve the efficiency of the fuel cell whencompared to composite plastic materials that have an average electricalconductivity of only a few hundred S/cm.

In addition to being electrically conductive, collector plates made ofbulk solidifying amorphous alloy also have good corrosion resistance,high inertness, and low permeability to hydrogen gas. The high corrosionresistance and inertness of these materials are useful for preventingthe collector plates from being decayed by undesired chemical reactionsbetween the collector plate and the mobile phases of the fuel cell. Theinertness of bulk solidifying amorphous alloy is also very important tothe life of the fuel cell because it doesn't tend to poison the catalystor react with the fuel and other chemicals in the fuel cell.

Another aspect of the invention is the ability to make collector plateswith isotropic characteristics. Generally non-isotropy in metallicarticles causes degraded performance for those portions of metallicarticles that require precision fit, such as in the seals, intricatechannels, and contact surfaces of the formed collector plates due tovariations in temperature, mechanical forces, and vibration experiencedacross the article. Moreover, the non-uniform response of the bipolarplates in various directions would also require extensive design marginsto compensate, and as such would result in heavy and bulky structures.Accordingly, the isotropic response of the collector plates inaccordance with the present invention is crucial, at least in certaindesigns, given the intricate and complex patterns and the associatedlarge surface areas and very small thicknesses of the collector plates,as well as the need to utilize high strength construction material.Providing such intricate channels in such large surface area and smallthickness plates from ordinary alloys will be difficult due to thepolycrystalline grainy structure of such alloys. For example, thecastings of ordinary alloys are typically poor in mechanical strengthand are distorted in the case of large surface area and very smallthickness. Accordingly, using metallic alloys for casting such largesurface areas with high tolerance in flatness is not generally feasible.In addition, for the ordinary metallic alloys, extensive rollingoperations would be needed to produce the collector plate sheet in thedesired flatness and with the desired high strength. However, in thiscase the rolled products of ordinary high-strength alloys generatestrong orientation, and as such lack the desirable isotropic properties.Indeed, such rolling operations typically result in highly oriented andelongated crystalline grain structures in metallic alloys resulting inhighly non-isotropic material. In contrast, bulk-solidifying amorphousalloys, due to their unique atomic structure lack any microstructure asobserved in crystalline and grainy metal, and as a result articlesformed from such alloys are inherently isotropic.

Another function of the collector plate is to provide structuralrigidity and complex patterns of pathways for fuel, oxidant reactants,coolant, and products, and suitable seals to contain them. By havingcomplex patterns, the desired flow rate, pressure drop, and residenttime can be achieved easily. The high strength, high elastic strainlimit and high surface finishes of the bulk amorphous alloys allow forthe ready production of collector plates with seals of relatively highintegrity utilizing various gaskets including metallic ones.

Another object of the invention is providing a method to producecollector plates in net-shape form from bulk solidifying amorphousalloys. By producing collector plates in net-shape form manufacturingcosts can be significantly reduced while still forming collector plateswith good flatness, intricate surface features comprising complexchannels, and high surface finish on the sealing areas.

One exemplary method of making such collector plates, as shown in theflowchart provided in FIG. 2, comprises the following steps:

1) Providing a sheet feedstock of amorphous alloy being substantiallyamorphous, and having an elastic strain limit of about 1.5% or greaterand having a ΔT of 30° C. or greater;

2) Heating the feedstock to around the glass transition temperature;

3) Shaping the heated feedstock into the desired shape; and

4) Cooling the formed sheet to temperatures far below the glasstransition temperature.

Herein, ΔT is given by the difference between the onset ofcrystallization temperature, T_(x), and the onset of glass transitiontemperature, T_(g), as determined from standard DSC (DifferentialScanning calorimetry) measurements at typical heating rates (e.g. 20°C./min).

Preferably ΔT of the provided amorphous alloy is greater than 60° C.,and most preferably greater than 90° C. The provided sheet feedstock haspreferably about the same thickness as the average thickness of thefinal collector plate. Moreover, the time and temperature of the heatingand shaping operation is selected such that the elastic strain limit ofthe amorphous alloy is substantially preserved to be not less than 1.0%,and preferably not being less than 1.5%. In the context of theinvention, temperatures around glass transition means the formingtemperatures can be below glass transition, at or around glasstransition, and above glass transition temperature, but always attemperatures below the crystallization temperature T_(x). The coolingstep is carried out at rates similar to the heating rates at the heatingstep, and preferably at rates greater than the heating rates at theheating step. The cooling step is also achieved preferably while theforming and shaping loads are still maintained.

Upon the finishing of the above-mentioned fabrication method, the shapedcollector plate can be subjected further surface treatment operations asdesired such as to remove any oxides on the surface. Chemical etching(with or without masks) can be utilized as well as light buffing andpolishing operations to provide improvements in surface finish so thathigh quality sealing and surface matching with other components can beachieved.

Another exemplary method of making collector plates in accordance withthe present invention comprises the following steps:

1) Providing a homogeneous alloy feedstock of amorphous alloy (notnecessarily amorphous);

2) Heating the feedstock to a casting temperature above the meltingtemperatures;

3) Introducing the molten alloy into shape-forming mold; and

4) Quenching the molten alloy to temperatures below glass transition.

Bulk amorphous alloys retain their fluidity from above the meltingtemperature down to the glass transition temperature due to the lack ofa first order phase transition. This is in direct contrast toconventional metals and alloys. Since, bulk amorphous alloys retaintheir fluidity, they do not accumulate significant stress from theircasting temperatures down to below the glass transition temperature andas such dimensional distortions from thermal stress gradients can beminimized. Accordingly, collector plates with large surface area andsmall thickness can be produced cost-effectively.

The above mentioned net-shape forming methods provide low cost collectorplates with functional surface features with intricate details (e.g.flow channels) at the order of 1.0 mm and preferably at much less than1.0 mm. Furthermore, these surface features can be achieved at hightolerances of flatness over large surface areas (e.g. 24″×24″ or larger)and small thickness and cross-sections (e.g. 1.0 mm or less). Theadvantages of bulk amorphous alloys and the above mentioned methodsbecomes increasingly crucial when these functional surface features(e.g. flow channels and seal joints) cover more than 20% of the overallplate area and preferably more than 50% of the overall plate area. Whenthese surface features cover more than 80% of the overall plate area,the economics of manufacturing these surface features can be the mostdominant factor and the advantages of bulk solidifying amorphous alloysand the methods described in this invention become more crucial.

Although specific embodiments are disclosed herein, it is expected thatpersons skilled in the art can and will design alternative amorphousalloy collector plates and methods to produce the amorphous alloycollector plates that are within the scope of the following claimseither literally or under the Doctrine of Equivalents.

1-25. (canceled)
 26. A conductive body comprising a cathode collectingface and an anode collecting face, wherein each face of said platecomprises a functional surface having a plurality of functional surfacefeatures formed thereon for transporting reaction materials between saidcathode and anode collecting face, and wherein at least the functionalsurface of said conductive body comprises an isotropic bulk solidifyingamorphous alloy having an elastic strain limit of at least 1.5%.
 27. Theconductive body of claim 26, wherein the conductive body is configuredto be incorporated in a device to generate electricity by chemicalreaction.
 28. The conductive body of claim 26, wherein said functionalsurface features includes at least one channel.
 29. The conductive bodyof claim 26, wherein the functional surface features have a size scaleof less than 1.0 mm and the functional surface of the conductive bodyhas a cross-section having a thickness of less than 1.0 mm.
 30. Theconductive body of claim 26, further comprising multiple heat exchangechannels between the cathode collecting face and the anode collectingface.
 31. The conductive body of claim 26, wherein the functionalsurface covers more than 50% of the overall conductive body area. 32.The conductive body of claim 26, wherein the surface features of theconductive body have an aspect ratio (depth/width) of from 0.1 to
 5. 33.The conductive body of claim 26, wherein the functional surface coversmore than 80% of the overall conductive body area.
 34. The conductivebody of claim 26, wherein the width of the at least one channel isbetween 100 μm to 2000 μm.
 35. The conductive body of claim 26, whereinthe bulk-solidifying amorphous alloy has an elastic strain limit ofabout 1.8% or more.
 36. The conductive body of claim 26, wherein thebulk solidifying amorphous alloy is described by the molecular formula:(Zr, Ti)_(a)(Ni, Cu, Fe)_(b)(Be, Al, Si, B)_(c), wherein “a” is in therange of from 30 to 75, “b” is in the range of from 5 to 60, and “c” inthe range of from 0 to 50 in atomic percentages.
 37. The conductive bodyof claim 26, wherein the bulk solidifying amorphous alloy is describedby the following molecular formula: (Zr, Ti)_(a)(Ni, Cu)_(b)(Be)_(c),wherein “a” is in the range of from 40 to 75, “b” is in the range offrom 5 to 50, and “c” in the range of from 5 to 50 in atomicpercentages.
 38. The conductive body of claim 26, wherein the bulksolidifying amorphous alloy sustains a strain up to 1.5% or more withoutany permanent deformation or breakage.
 39. The conductive body of claim26, wherein the bulk solidifying amorphous alloy has a high fracturetoughness of at least 20 ksi-in0
 5. 40. The conductive body of claim 26,wherein the bulk solidifying amorphous alloy has a ΔT of 60° C. orgreater.
 41. The conductive body of claim 26, wherein the conductivebody is a collector plate.
 42. The conductive body of claim 26, whereinthe conductive body is a current transferor, separator, cathode, anode,end plate, or any combination thereof.
 43. The conductive body of claim26, wherein conductive body has functional patterns on a majority of asurface area of the conductive body.
 44. The conductive body of claim26, wherein the bulk-solidifying amorphous alloy comprises a ferrousalloy.
 45. The conductive body of claim 26, wherein the bulk-solidifyingamorphous alloy comprises a Ni-containing alloy.
 46. A conductive bodycomprising a surface feature on a near-to-net shape form on at least oneportion formed of a bulk-solidifying amorphous alloy having an elasticstrain limit of about 1.2% or more, a high hardness value of at leastabout 7.5 GPa, a glass transition temperature of 500° C. or above,wherein the conductive body is configured to be incorporated in a deviceto generate electricity by chemical reaction.
 47. The conductive body ofclaim 21, wherein the bulk-solidifying amorphous alloy comprises anickel-base alloy.
 48. The conductive body of claim 21, wherein thebulk-solidifying amorphous alloy comprises a ferrous alloy.
 49. Theconductive body of claim 21, wherein the bulk-solidifying amorphousalloy is a ferrous alloy comprising Fe, Ni and Co.
 50. The conductivebody of claim 21, wherein the bulk-solidifying amorphous alloy has theglass transition temperature of 550° C. or above.
 51. The conductivebody of claim 21, wherein the bulk-solidifying amorphous alloy comprisesa composition being represented by the following general formula:Ni_(a)(Zr_(1-x)Ti_(x))_(b)Si_(c) where a, b and c are atomic percentagesof nickel, zirconium plus titanium and silicon, respectively, and x isan atomic fraction of titanium to zirconium, wherein; 45 atomic %≦a≦63atomic %, 32 atomic %≦b≦48 atomic %, 1 atomic %≦c≦11 atomic %, and0.4≦x≦0.6.
 52. The conductive body of claim 21, wherein thebulk-solidifying amorphous alloy comprises a composition beingrepresented by the following general formula:Ni_(d)(Zr_(1-y)Ti_(x))_(e)P_(f) where d, e and f are atomic percentagesof nickel, zirconium plus titanium and phosphorus, respectively, and yis an atomic fraction of titanium to zirconium, wherein; 50 atomic%≦d≦62 atomic %, 33 atomic %≦e≦46 atomic %, 3 atomic %≦f≦8 atomic %, and0.4≦y≦0.6.
 53. The conductive body of claim 26, wherein thebulk-solidifying amorphous alloy further comprises V, Cr, Mn, Cu, Co, W,Sn, Mo, Y, C, B, P, Al, or combinations thereof.
 54. A device togenerate electricity by the chemical reaction comprising: a conductivebody having a cathode collecting face and an anode collecting face,wherein each face of said plate comprises a functional surface having aplurality of functional surface features formed thereon for transportingreaction materials between said cathode and anode collecting face, andwherein at least the functional surface of said conductive bodycomprises an isotropic bulk solidifying amorphous alloy; a cathodedisposed adjacent to the cathode collecting face of the conductive body;and an anode adjacent to the anode collecting face of the conductivebody.
 55. The device of claim 29, wherein the conductive body forms atight seal within the device to prevent leakage of liquid and gaseousmaterial between the anode and the cathode.
 56. The device of claim 29,wherein the device further comprises an interfacial surface between thecathode and the anode, wherein said interfacial surface has a pluralityof heat exchange channels.
 57. The device of claim 29, wherein theconductive body comprises a current transferor, separator, cathode,anode, end plate, or any combination thereof.